klosin



1956 J. J. KLOSIN, JR

COMPRESSION TYPE ELECTRIC CONNECTOR 2 Sheets-Sheet 1 Filed Aug. 11, 1950 1. ATTORNEY w y T0 NL WK m1 M MY B United States Patent COMPRESSION TYPE ELECTRIC CONNECTOR John J. Klosin, Jr., Yonkers, N. Y.

Application August 11, 1950, Serial No. 17 3,977

7 Claims. (Cl. 174-94) The invention relates to electric wire connectors; it relates, more particularly, to a connector of the compression type for connecting a branch or tap wire to a through or run wire without requiring cutting the latter wire, although not limited to such use.

Compression type connectors for connecting electric wires have gone into extensive use as they have the best mechanical and electrical characteristics. The connector is usually made from a ductile metal and is compressed about the wire conductor with specially made tools capable of exerting great pressure. These tools have die grooves that control the shape of the compressed connector. Compression connectors are considered superior to splices using nuts and bolts since the latter usually contact the wire in about two places where the circular conductor is tangent to the clamp groove. Compression type connectors, on the other hand, contact the conductor over a great part of its surface, resulting in greater mechanical strength and higher electrical efiiciency. In addition, compression connectors resist vibration, withstand overloads and short circuits, and resist interior corrosion much better than bolt type connectors.

In practice today, compression type connectors find their greatest use as line splices; that is to say, the conductor ends are placed in either end of the connector tube and the connector is then compressed about the conductor. Other present large uses for compression type connectors are as terminals. Here the end of the conductor is inserted into the connector tubing; the tubing has a flattened end to provide a terminal pad through which a suitable bolt passes for connection to a binding post or the like.

The present invention relates to a compression type connector which will connect a tap conductor to a continuous run conductor at any point in a wire span, without requiring cutting the latter. According to a preferred form of the invention, the connector is made from a blank of sheet metal having a body portion and two oppositely extending, offset leg portions. The body portion is bent to form a saddle adapted to straddle the through conductor. The leg portions are bent oppositely with respect to the saddle portion to form loops which, in the finished connector before applying to the wires, may be wholly disaligned. The ends of the legs may be soldered, brazed or mechanically interlocked or jointed to the adjacent leg portions to form closed seams. To use such a connector, the saddle portion is placed over the through conductor; then the two loops are brought into line and the end of the branch conductor is threaded through the aligned loops. The connector is then suitably compressed by a suitable tool to tightly key or wedge the saddle portion to the through Wire and the loops to the branch wire.

The invention also consists in certain new and original features and combinations hereinafter set forth and claimed.

Although the novel features which are believed to be characteristic of this invention will be particularly pointed out in the claims appended hereto, the invention itself,

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as to its objects and advantages, and the manner in which it may be carried out, may be better understood by referring to the following description taken in connection with the accompanying drawings forming a part hereof, in which:

Fig. l is a vertical elevation of the connector according to the invention, shown applied to the wires to be connected;

Fig. 2 is a section taken on the line 22 of Fig. 1;

Fig. 3 is a perspective of the blank sheet metal from which the connector is made;

Fig. 3a is a section taken on the line 3a3a of Fig. 3;

Fig. 4 is an end elevation of the finished connector, but before being applied to the wires;

Fig. 5 is a side elevation of the connector shown in Fig. 4;

Fig. 6 is a bottom plan view of the connector shown in Fig. 4;

Fig. 7 is a modified form of blank having three legs, all the same width;

Fig. 8 is a side elevation of the blank of Fig. 7 after it is rolled into a connector;

Fig. 9 is a further modified form of blank having four legs, all the same width;

Fig. 10 is a side elevation of the blank of Fig. 9 after it is rolled into a connector;

Fig. 11 is an end elevation of a further form of connector in which loops of metal tubing are brazed to the legs of a metal sheet;

Fig. 12 is a side elevation of the connector shown in Fig. 11 after bending into shape;

Fig. 13 is a blank from which a further modified form of connector is made;

Fig. 14 is an end view of a connector made from the blank in Fig. 13 and illustrating how it is applied to the through wire;

Fig. 15 illustrates an intermediate step in applying the connector of Fig. 14 to the through wire; and

Fig. 16 illustrates the connector of Figs. 13 to 15 applied to connect the through wire to a branch wire.

In the following description and in the claims, various details will be identified by specific names for convenience, but they are intended to be as generic in their application as the art will permit.

Like reference characters denote like parts in the several figures of the drawings.

in the drawings accompanying and forming part of this specification, certain specific disclosure of the invention is made for purposes of explanation, but it will be understood that the details may be modified in various respects Without departure from the broad aspect of the invention.

Referring now to the drawing, the blank shown in Fig. 3 is suitably cut from sheet or strip metal. The metal is preferably soft and ductile. That is to say, it is malleable. It is preferably made of copper or brass, lthough it may be made of other materials, such as aluminum. If copper or brass, it may be silver or tin plated; if aluminum, it may be tin plated.

The blank comprises a body ill with oppositely extending offset legs 11 and 12. It has offset edges 13 and 14. The blank should have all sharp edges and corners removed. It will be noted that the blank is of such shape that a series of them may be cut from stock material with a minimum of waste.

The finished connector, as shown particularly in Figs. 4 to 6, is made up by bending the body to form a saddle portion 10. The leg portions are bent, oppositely with respect to the body 10, to form loop portions 11 and 12. The ends of the legs are integrally connected to the adjacent portions of the legs to form closed seams indicated by 15. The connection .of the formed loops to the legs 3 may be made by brazing with silver solder in the case of copper, and with appropriate material in the event the connector is made of aluminum or other material. This connection may also be made by mechanical interlocking or'joined when formed without use of brazing or soldering.

If desired, before fabricating the connector to the finished shape shown in Figs. 4 to 6, the stock material may be suitably knurled by a diamond knurl to form relatively sharp points on the surfaces. The blank may be knurled continuously on both faces or, if desired, only on the parts of the faces which are adapted to contact the conductors as shown. This means that the body 10 is knurled on one face, While the legs 11 and 12 are knurled on the opposite face.

T apply the connector to the wires to be connected, the wires are first suitably prepared, in a manner well known to those skilled in the art. The connector is applied to the through, or run, cable 17 by placing the saddle portion thereover. The loops 11 and 12 are then brought into line, and the tap cable or branch wire 18 is threaded into the aligned loops, as indicated in Figs. 1 and 2. The aligning of the loops 11 and 12 serves to form the splice, when viewed on end, into an 8-configuration, as shown particularly in Fig. 2.

The connector is then compressed by a suitable tool (not shown), as for example, a tool similar to that shown in Dickie et a1. Patent 2,149,209, dated February 28, 1939. The die grooves in such a tool deform or compress certain areas indicated at 20 of the connector, leaving other areas indicated at 21 less deformed, as indicated especially in Figs. 1 and 2. This compression tightly squeezes all parts of the connector against the inserted conductors, and in case the connector has a knurled surface, it causes the diamond shaped projections to bite into the surface of the metal conductors, forming joints of increased mechanical strength and decreased electrical resistance.

It will be understood that any type of well-known compression tool may be used, as for example, the bolt cutter type, or a hydraulic press type. Also the compression pattern that is, the parts of the connector deformed by compression, may be other than that shown for purposes of illustration.

Thus, a compression type connector is provided which avoids any open seam. That is to say, the branch conductor is entirely surrounded by closed loops of metal which cannot open up. Similarly, the bringing of the loops into alignment, and the threading therein of the branch conductor 18, acts to close the saddle portion 10, forming a closed loop around the main wire 17, in the sense that the body and legs entirely surround the main conductor and the seam is closed by the crossing of the legs 11., 12 adjacent offset edges 13, 14.

Since all seams are closed, there is no open seam for line vibration to widen. The connector may be used equally well on overhead wires and in underground cables. Furthermore, it is not necessary to cut the main, or through, wire and the wire is not otherwise injured by application of the connector. It provides maximum mechanical strength with minimum electrical resistance over long periods of time. It may also be used to connect two end wires, one wire being placed to the saddle portion and the other wire in the aligned loops.

The connector can handle either solid or stranded wire. The main wire may be of the same type material, and size as the branch Wire; or, the branch wire may differ in type or in size or basic material. The connector may be made in a great variety of sizes handling anywheres from, for example, No. 20 A. W. G. (American Wire Gage) to 1500 MCM (1000 circular mills). It may handle current from less than three amperes to 1000 amperes or over. In practice, the connector will be made in certain standard sizes, each size being able to adapt certain ranges of wire sizes.

Another advantage of the invention is its ability to reduce galvanic action when connecting conductors of unlike material. It will be noted that the construction of the connector is such as to prevent actual physical contact of one conductor with the other. This is of advantage in reducing galvanic action when the conductors to be connected are of unlike material. For example, if one conductor is copper and the other aluminum, the connector may be tin plated. This will substantially neutralize or eliminate any galvanic action because tin is recognized in the industry as being of an electrolysis inhibiting material as between copper and aluminum.

Referring now to Figs. 7 and 8, a modified form of connector is illustrated. This form follows quite closely the main form shown in Figs. 1 to 6 except that three legs are provided instead of two. In this form, the body portion is indicated by 30 and the three legs are indicated by 31, 32 and 33. To form the connector, the body 30 is bent to form the saddle portion 30 and the three legs are bent to form loops 31, 32 and 33. The legs 31 and 33 are bent oppositely from the middle leg 32, to form the respective loops. The ends of the .legs are integrally connected, as by brazing, to the adjacent portions of the legs to form closed seams in a manner similar to the closed seams 15 in Figs. 1 to 6. The connector is applied to the wires in the same way as the connector in Figs. 1 to 6 except that it is necessary to align all three loops 31, 32 and 33 before inserting the branch wire (not shown) through all three loops.

Referring now to Figs. 9 and 1-0, in this form the connector is provided with a body portion 40 and four legs 41, 42, 43 and 44. The legs 41 and 43 on the one hand, and legs 42 and 44 on the other hand, are bent oppositely to form the loops 41, 42, 43 and 44. The ends of the legs may be integrally connected, as by brazing, to the adjacent portions of the legs to form closed seams similar to the closed seams 15 in Figs. 1 to 6. The manner of applying the connector to the wires is the same as that of Figs. 1 to 6 except that it is necessary to bring all four loops 41 to 44 into line before inserting the branch wire (not shown) through all four loops.

Referring now to Figs. ll and 12, here the body 50 of the connector has a pair of offset legs 51 and 53 similar to the legs 11 and 12 of Figs. 1 to 6 except that the legs are shorter. To each leg is integrally connected, as by brazing, a short piece of tubing 52 and 54, respectively.

The manner of applying'this connector to the wires is similar to that of Figs. 1 to 6. Saddle 50 .is placed over the through conductor (not shown); then the two closed loops 52 and 54 are brought into line and the branch conductor (not shown) threaded through the aligned loops.

Referring now to Figs. 13 to 16, here the blank comprises a relatively narrow body 60 and relatively long legs 61 and 62. The connector is made up by bending the legs 61 and 62 toward each other; the extreme ends of the legs 61 and 62 are bent to form loops 63 and 64 respectively. The ends of the loops are brazed to the adjacent parts of the legs 61 and 62 to form closed seams 65, as indicated.

To apply the connector of Figs. 13 to 16 to the wires, the connector is first applied to the through wire 17a in inverted position, somewhat as indicated in Fig. 14. The legs 61 and 62 are then bent toward each other in the direction of the arrows 66 so as to snugly wrap the connector around the through conductor 17a somewhat as indicated in Fig. 15. The legs 61 and 62 are then further bent, as indicated by the arrows 67 in Fig. 15 to bring the two loops 63 and 64 in line. The branch conductor 18a is then threaded through the aligned loops 63 and 64, as indicated in Fig. 16. i

In all of the modifications illustrated by Figs. 7 to 16, it will be understood that, after applying the connector to the conductors in the manner described above, the connector will then be compressed by a suitable tool to tightly squeeze contacting parts of the connector against the inserted conductors in a manner similar to that described concerning Figs. 1 to 6 above. It will be understood also that advantages and uses pointed out in connection with Figs. 1 to 6 also apply to modifications shown in Figs. 7 to 16.

While certain novel features of the invention have been disclosed herein, and are pointed out in the annexed claims, it will be understood that various omissions, substitutions and changes may be made by those skilled in the art without departing from the spirit of the invention.

What is claimed is:

1. In a compression connector for a through wire, an enveloping portion adapted to enclose and grip a first conductor, a plurality of opposed loops connected to said enveloping portion extending outwardly of the enveloping portion, said loops being adapted to be brought into coaxial contiguous alignment with each other to receive a second conductor, said enveloping portion being of sufficiently ductile material to permit it to be compressed about said first conductor, said loops being of sufiiciently ductile material to permit them to be compressed about said second conductor.

2. A compression through type connector having a body portion for substantially surrounding and gripping a first through conductor, oppositely extending leg portions providing opposite offset edges on said body portion, said body portion being bent to form a saddle to grip and straddle a through wire and to be compressed around said through wire, said leg portions being bent outwardly relatively of each other to form loops with the free ends of said leg portions disposed adjacent their respective leg portions, said leg portions forming reverse curves with respect to said saddle, said loops being yieldable so as to be brought into co-axial alignment, with said leg portions further crossing near said body edges, to receive a branch wire, said loops being adapted to be compressed against the branch wire and surrounding the same.

3. A compression through type closed seam connector made from a sheet metal blank, comprising a comparatively wide body portion with offset, oppositely extending leg portions, said leg portions being about one-half the width of said body portion and providing opposite offset edges on said body portion, said body portion being bent to form a saddle adapted to straddle a through wire and being sufiiciently malleable to be compressed around said through wire, said leg portions being bent outwardly to form closed loops, with the free ends of said leg portions disposed adjacent their respective leg portions near the juncture of said leg portions and said body portion, said leg portions forming reverse curves with respect to said saddle, said loops being adapted to be brought into coaxial alignment, with said leg portions crossing near said body edges, to receive a branch wire, said loops being sufiiciently malleable so as to be compressed against the branch wire, the free ends of said leg portions being connected to their respective leg portions to form closed seams.

4. A compression through type connector comprising a wrap portion with projecting legs, said wrap portion resting on a first conductor and being malleable so as to be wrapped around said first conductor and grip the same, loops forming said legs, said loops being malleable so as to be brought into alignment, and after the wrap portion is wrapped around said first conductor, said loops are adapted to receive a second conductor, said connector having electrolytic corrosion inhibiting surfaces for contacting conductors of unlike metals, said connector holding said conductors of unlike metals in spaced relation to prevent galvanic corrosion.

5. A compression through type connector having a saddle for substantially surrounding a first through conductor, and a plurality of loops extending integrally from said saddle for substantially surrounding a branch conductor when said loops are brought into relative alignment, said saddle and loops being of malleable material to permit compressing the same around the first and branch conductors respectively to tightly hold the same respectively in spaced relation, the loops when compressed around the branch conductor having their free ends coming into contact with the compressed saddle, but on opposite sides thereof.

6. A connector according to claim 5, in which the free ends of the loop are joined to the saddle to form a substantially integral, closed unit.

7. A connector according to claim 5 in which the conductor contacting portions of the saddle and loop respectively, are coated with an electrolytic inhibiting material.

References Cited in the file of this patent UNITED STATES PATENTS 516,291 Aylworth et al. Mar. 13, 1894 557,037 Toquet Mar. 24, 1896 909,481 Tregoning Jan. 12, 1909 1,070,948 Dodd Aug. 19, 1913 1,982,501 Douglas Nov. 27, 1934 2,149,209 Dickie et a1 Feb. 28, 1939 2,190,824 Cook Feb. 20, 1940 2,353,732 Kingsley July 18, 1944 FOREIGN PATENTS 173,419 Great Britain Jan. 5, 1922 

